Military Hand book on NDT.pdf

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MI L- HDBK-72811

16 December 1985

SUPERSEDING

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MILITARY HANDBOOK

NONDESTRUCTIVE TESTING

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Department of Defense

Washington, DC 20301

MIL-HDBK-728

Military Handbook af Nondestructive Testing

16 December 1985

1.

This Military Handbook is approved for use by all Departments and

Agencies of the Department af Defense.

2. This publication was approved on 21 October 1985 for printing and

inclusion in the military standardization handbook series.

3.

T~i: d~~~efit pr~vi,je~ b~~i~ and fund~~e~t~] i~f~~ati~” ~~

nondestructive testing, inspection and evaluation useful durin~ all phases of

the DoD hardware’s life cycle.

4.

Every effort has been made to reflect the latest information on

nondestructive examination.

It is the intent to review this handbook

periodically to insure its completeness and currency. Fleneficialcmments

(recommendations, additions, deletions) and nny pertinent data which may be of

use in inp?ovin~ this document should he nddressed t~:

Director, U.S. AririY

Materials Technology Laboratory, ATTN :

SLCPIT-MSR-ES, Waterto m, MA 02172-0001

by using the self-addressed Standardization Document Impr~vement Proposal

(DD Form 1426) at the end of this document or by letter.

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FOREWORD

This handbook provideg to all Department of Defense (DoD) personnel

information, facts, and principles on the science of nondestructive testing,

inspection, and evaluation. By proper use of this science, the safety, the

reliabili ty, and the efficiency of the procurement and use of all DoD material

and hardware will be increased. This handbook information should be ugeful

during all phases of the L?uDhardware’ s life cycle including production,

maintenance, and repair of the hardware.

Thie handbook, by combining the existing nondestructive testing handhoks

and releted materials from all DoD agencies into one document, should help to

establish unity in the nondestructive testing area within and between all the

‘itienki~iof the“DoD.

Th6 6i@fiiXition and- lo”ose-leafformat will”make it easy

to correct, update, and tailor to fit individual, needs within the DoD.

Since the handbook’.geffectiveness depends upon continuous, feedback from

its users,

individuals are encouraged to contribute comments and suggestions

by filling in and mailing Form DD 1426 provided at the end of this document.

(;

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TABLE OF CONTENTS

2EEEz

1.

General Information

2. Eddy Current Testing

3.

Liquid Penetranc Testin&

4.

Magnetic Particle Testing

5.

Radiographic Testing

b.

Ultrasonic Testing

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Section

1.0

1.1

1.2

1.2.1

1.2.2

1.2.3

1.2.4

1.2.5

1.3

1.4

1.4.1

1.4.2

1.4.3

1.4.4

1.4.5

1.4.6

1.4.7

1.5

1.6

1.7

1.8

(.

1.9

‘MIL-HDBK-728/l

TABLE OF CONTENTS - CHAPTER 1

“

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii

SCOPE . . . . . . . . ...’.. . . . . . . . . . . . . . . . . 1.1-1

Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1-1

USERS GUIDE. . . . . . . . . . . . . . . . . . . . . . . . . .1.2-1

Handbook Organization . . . . . . . . . . . . . . . . . . 1.2-1

References. . . . . . . . . . . . . . . . . . . . . . . .1.2-1

Index . . . . . . . . . . . . . . . . . . . . . . . . . .1.2-1

Format forDefinitione . . . . . . . . . . . . . . . ...1.2-1

Handbook Revisions . . . . . . . . . . . . . . . . . . . . 1.2-1

Definitions for NDT, NDI, and NDE . . . . . . . . . . . . . . . 1.3-1

General Principles and Guidelines . . . . . . . . . . . . . . . 1.4-1

C6rierel Principle and Guidelines for Using NDT . . . . . 1.4-1

Principles and Guidelines for Adninistratore . . . . . . . 1.4-4

Principles and Cuideline8 for Designers . . . . . . . . . 1.4-6

Principles and Guidelines for Production Engineers . . . . 1.4-?

Principles and Guidelines for Quality Aaeurance Personnel

1.4-9

Principles and Guidelines for NDT Engineers . . . ... .

.1.4-11

Principles and Guidelines for NDT Technicians . . . . . . 1.4-13

Choosing Tegt Methods . . . . .’. . . .. . . . . . . . . . .. 1.5-1

GIOSSa~ . . . . . . . . . . . . . . . . . . . . . . . . ...1.6-]

Bibliography . . . . . . . . . . . . . . . . . . . . .. . . .. 1.7-1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.8-I

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . ...1.9-1

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List of Revisions:

Tnis is the first issue, witk:n> revisi>ns, appraved for

publication 16 December 1935

List sf Current Pages:

Page 11>.

i to iv

l-i to l-ii

1.1-1 to 1.1-2

1.2-1 t> 1.2-2

1.3-1 to 1.3-2

1.4-1 t~ 1.4-2

1.5-1 to 1.5-14

1.6-1

t.?

1.6-6

1.7-1 t~.1.7-2

1.$3- to 1.8-8

1.9-1 ta 1.9-2

2-i t~ 2 ii

2.0-1 to 2.0-2

2.1-1

to

2-1-2

2-2-1 to 2.2-12

2.3-1 t> 2.3-8

2.4-1 to 2.4-10

2.5-1 t~ 2.5-2

2.6-1 to 2-6-2

7.7-1 to 2.7-2

2.8-1 to 2.8-2

?.9-1 t) 2.9-A

,?.10-1 t..3.10-2

2-II-I to ?.il-2

3-i to ?-ii

-5.0-1to 3.0-2

3.1-1 tO 3.1-2

3.2-1 t$ 3.2-6

3.3-1 to 3.3-8

3.4-1 to 3.4-1o

3.5-1 to 3.5-2

3.6-1 t~ 3.6-2

3.7-1 t03.7-4

3.8-1 ts 3.8-2

3.9-1 to 3.9-6

3.10-1 to 3.10-2

3.11-1 tO 3.11-2

Latest Issue Date

16 December 1985

16 December 1985

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Page 110.

Latest Issue Date

4-i to 4-ii

4-071 to 4.0-2

4.1-1 to 4.1-2

4.2-1 to 4.2-12

4.3-1 to 4.3-6

4.4-1 to 4.4-14

4.5-1 to 4.5-2

4.6-1 to 4.6-2

4.7-1 to 4.7-2

A.8-1 to 4.8-2

4.9-1 to 4.9-8

4 .10-1 to 4.10-2

4.11-1 to 4.11-2

5.0-1 to 5.0-2

5.1-1 to 5.1-2

5.2-1 to 5.2-18

5.3-1 to 5.3-16

5.4-1 to 5.4-6

5.5-1 to 5.5-2

5.%-1 ?? 5.6-2

5.7-1 t3 5.7-2

5.t3-ito 5.t3-12

5.9-1 t9 ?.9-14

5 .10-1 t9 5.10-2

5.11-1 to 5.11-4

6.0-1 t> 6.0-2

6.1-1 to 6.0-2

6.2-1 to 6.2-22

6.3-1 to 6.3-2

6.4-1 to 6.4-24

6.5-1 to 6.5-12

6.&l to 6.6-2

6.7-1 to 6.7-4

6.8-1 t.>6.8-4

6.9-1 to 6.9-8

6.10-1 to 6.10-2

6.11-1 to 6.11-2

16 December 1985

16 December 1985

16 December 1985

16 December 1985

16 December 1995

16 December 1985

16 December lq85

16 December 1995

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16 December 1’385

16 December 1985

16 December ?35

16 December 1’2S5

]6 December l?~~

16 leccnber1?95

16 December IW5

16 December 1985

16 December 1’285

16 December 19P.5

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1.0 scoPi

1.1 *. Although this handbook is provided as a guide to all those

employed in nondestructive testing (NDT), it will be of specific interest to

administrators, designers, production engineers, quality assurance personnel,

and nondestructive test engineers and technicians. lt has been formulated to

cover both broad and specific applications of NDT, so as to satisfy

individuality, as well as conformity, of interests and knowledge smong the

divisions of responsibility in NDT. Not everyone will be interested in all of

the specially identified sections.

However, to obtain optimum benefits, it is

recommended that users of this document review it in ita entirety, while

paying particular’at tention “to those sectiori:,often identified by a heading

or subnote, which may be of specific concern to them.

The handbook, which currently inco~poratez Seneral principles and procedures

(as well as safety items) of eddy current, liquid penetrant, magnetic

particle, radiographic and ultrasonic testing, will be updated, to include

chapters on other NDT methods as they become appropriate.

It must be emphasised that this handbook is not a training manual. Nor can it

replace other written directives, procedures or specifications.

However, it

can serve aa a reaciy reference to the important principles and facts relating

to the employment of nondestructive testing, inspection and evaluation. It

can be used to refresh one’s me”ory of a particular NDT principle or

(

relationship, to double check or establish a particular fact, or to review the

main ideas,

concepts or completeness of a particular approach.

..

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1.2 USERS CUIDE

1.2.1 NANDBOOi O&NIZATIOti ‘“

This handbook, which is intended to make chaages, additions and tailoring

easy, use$ chapters as independent organizational elements.

Each chapter is

reasonably complete and self-contained with respect to each specific topic

presented and is divided into numbered eections and subsections for ease of

~~ reference and use.

Pages ere numbered consecutively within each section:”sections are numbered

consecutively within each chapter; and chaptera are numbered consecutively

within the handbook. The publication or revision date of each page is loceted

at the bottom inner edge of the page.

Tables, monographs. drawings, and other illustrative material are nO~allY

presented within the text.

They are identified by the number of the section

in which they first are referenced, followed by a sequence riumberin

parentheses:

e.g. , the first Table in section 5.2 is designated as Table 5.2

(1), the second Table in the same section is designated Table 5.2(2), etc.

The general Table of Contents listing all chapters in the handbook is found on

page iv.

A.Table of Contents listing all sections in a chapter is located at

the beginning of each chapter.

1.2.2

REFERENCES

(

There are two t.yp.?~f references used in this handbook; (1) cross-references

to paragraphs in the handbook, and (2) references to other publications which

are the sources of specific ateriel.

Cross-references are uged within this

handbook wherever poesible to avoid duplication of information.

1.2.3

INDEx

A detailed index of subject matter, keyed to section numbers, is provided at

the end of each chapter.

1.2.4

FORFIAT FOR DEFINITIONS

Terms which apply to a specialized area and are not.defined in standard

publication are usually explatned in this handbook. If a term is used only

once or infrequently, it is explained in the text whe~ it Occurs-

If it is

used frequently throughout a chapter, it will appear.in the glossary at the

end of the chapter.

Common terns, or those whose definitiona appear in

standard glossaries or dictionaries, ore not normally included in this

handbook.

.

1.2.5

RANDBOOK REVISIONS

“Every effort haa been made to reflect the latest imfonnation on eddy current,

liquid penetra6t, magnetic particle, radiographic, and ultrasonic testing. It

i

ia the intent to review this handbook periodically to engure ita completeness

and currency. Each revision will include a revised List of Current Pages

which will show the latest issue of each page of the handbook.

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1.3

... .. ....’. ,,’ ‘.

)

Although extensive definitions are included in each chapter, several basic

terms --

Nondestructive Testing (NDT),

Nondestructive Inspection (NDI), .snd

Nondestructive Evaluation (NDE) -- are worthy of special discussion.

Any tes,ting,inspection, or evaluation that does not cause harm to or impair

the usefullnesa of an object satisfies the

eaning of the word

“nondestructive.” In common usage,

testing often refers just to test

ethods

and test equipment with only a general reference to materials and/or parts.

Inspection relates to specific written requirements, procedures, personnel,

standards,

and controls for the testing of a particular material or a specific

part.

Evaluation is concerned with the decision~making process, the

‘d~fetiination of the meaning of the ras”lt’g, or the final acceptance or

rejection of the material or part und may be qualitative or quantitative.

When only qualitative or ralative values are required, the “se of reference

standards is minimized.

For quantitative evaluations, however, ertensiive “se

of reference standards and controls is often involved.

Although these distinctions between NDT, ND1, and NDE can be (and often are)

made,

the terms are also often interchanged.

In order to evaluate, the

results of an inspection must be available.

In order to have the results of

an inspection, a test must “be conducted.

And no test or inspection is really

complece without an evaluation.

As a result of these interdependancies, no

(

strict differentiations batween these terms are made in this handbook.

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1.4 GENERAL PRINCIPLES AND GUIDELINES

The following section presents principles and guidelines for the general

employment of NDT, as well as for specific NOT disciplines.

In some cases,

the material is repetitive, since several disciplines are involved in similar

activities.

It is important, however, to understand differences, as well as

similarities, between the disciplines, and to recognize how cooperation

between these disparate disciplines is vital to the overall success of NDT.

Guides for applying specific NDT methods are contained in the chaptera for

those.specific methods. The principles and guides covered in this section are

all summarized in tables at the end of each subsection, and can ba used as

handy raference guideline.

1.4.1

C ZHERALFRINCIF’LEX AXD GIJIDELIiJI?SO17USING ND’T

Before specifing the use of NDT in any program, “several things .should be

considered. First, detenaine exactly why, or if, NIX’is z-squired. There are

many reasona why NDT may be desired or necessary:

to increase the production

rate (by assuring a higher success rate), to increase reliability, “to improve

or maintain safety,

to meet legal requirements, to differentiate or identify

improved processing methods, or to detect changes in the product before they

become a problem.

(“

There is a danger that specifying NDT has become routine practice rather than

the result of a real need:

i.e., it was done this way last time: it is always

done this way; they did it,

we have to do it; everyone else is doin& it; or

let’s do it just to be safe.

Sometimes NIYTis specified just for

administrative reasons: the contract requires it.

Often, although the use of NDT is specified to satisfy a legitimate

requirement, it may actually be inappropriate.

For example, the ultimate

purpose of a test may be to ensure that a part has it? re,quireddesigned

stren~th.

NDT tests are often ueed to accomplish this determination, even

though they do not directly measure the strength of a ?art: its strength can

only be inferred by the absence of certain detectable flaws. A simple proof

tast, which does not require any assumptions, standarda, correlations, or

other inferred relationships, would have been much more appropriate. The

principle here being that an affort 9hould alwaya be made to dete.mine the

critical properties directly.

Inferring the rasults by secondary means should

only be considered when specific circumstances warrant.

Since al,moatall ND’T

ethods are indirect or

“secondary””

types of’measurements, they are often best

replaced by more direct methods. Direct methods are not relevant to

nondestructive test methods deployed in end items where destructive tests are

not feasible, i.e. thermal damage to aircraft structure.

Whatever the reasons given for specifying ND1’,

it ia important that everyone

involved in NDT recognizes and evaluates those reaaons realistically so that

those rssponsiblezfor implementation are able to provide logical and affective

responses.” Certainly, all progriuns should consider specifying the use of NDT;

however, its automatic use should be evoided. NDT should always have an

identifiable purpose that justifies its expense.

The reasons for the

requirement of NDT will often affect all other decisiong.

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,.

Ultimately,

the decision on the proper limitation for allowable flaw size must

be made by the d“esigner working in cooperation with production, stress, and

msterial engineers.

They must determine the types of flaws expected and the

maximum allowable flaw limits required to,achieve or maintain design goala.

Only after this groundwork has been completed, can the proper decisions ”for

the requirements for NDT be made.

Depending upon the NDT capabilities that

exist, trade-off studies may be necessary to ensure that the critical flaws,

“. at their specified limits, can be effectively and reliably detected.

Although

trade-off studies and decisions should be accomplished at the design level,

they often are not because of insufficient infnnmation.

When “not made at the

design level, choices becnme more limited, often resulting in either a

reduction of the original design goals or the acceptance of unreliable

prnducts.

Once tileseflaws and flaw limitations have been determined, then NDT engineers

must respond by finding answers to nre queetions -- What NDT method must be

used? What equipment, persotiel, and contrnls are necessary? .Many times, one

method alone may not be adequste.

No ,test or inspection is complete” withnut the proper and adequate evaluation

of the data. If a permanent test record is required, the documentation must

be considered in the NDT test itself.

Since snme methods of NDT.do not

provide results in terms of a permanent record, specifying permanent records

“’or documented proof of the passing nf a test drieslimit the choices available.

(

This limitation nf test methnds should be considered befnre such requests are

made.

Principles and guidelines for specific disciplines are given in the paragraphs

that fnllow. The assignment nf principles and guidelines to specific

disciplines clarifies who is responsible fnr implementing the concepts nf NDT

and hnw each discipline must suppnrt the other if success is to be achieved.

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Table 1.4(1). General

principles and guidelines”for NDT.

1.

Determine exactly why NDT is required.

2. If unreasonable, to remove the HDT requirement or minimize it.

3.

If the need for NDT cannot be denied, design for inspection.

4.

Determine the proper plsce(s) in the life cycle for performing NDT.

5.

Establish critical flaw limitations in quantitive items. These

limitations cannot be:

“’Noflaws allowed” or “Find the smallest

possible flaws.”

They should be in terms such as ‘“Nocracks shall

exceed a length of 4 mm in any direction or “’anypores or combination

of contiguous pores that equal or exceed the volume of a 3 mm sphere

shall be rejected”’.

6.

Determine the appropriate method(s), equipment, personnel, standards,

and controls.

Remember, most NDT methods do not reveal flaws

directly und interprc+.ation is ~ften possible only through the use of

proper standards. NDT methods usually only find indications or

differences.

These indications .re significant only to the degree

that they can be interpreted correctly.

Also remember that complete

answers (positive answers) cann>t always be obtained by a single

inspection method.

Two or more meth~ds may be required for a

complete analysis.

7.

Establish the means for complete, pr~per, or adequate evaluations

(to include reports end documentation).

1.4.2

PRINCIPLES ANP GUIDELINES FOR ADMINISTRATORS

The s,]ceess for any NPT pr~ernm will alwnys rest l]ponman~eers. It is the

m:ln.accrwhl muxt decidr? the overz?

11 Rsals, the proper divisim of the

availahl? funds, and the coordination that must be maintained.

It is the

mnna~er krhodetermi~es the decree to which the total life cycle of a component

is considered -- including the producti~n of raw stock to the final salvaee of

worn-out parts. The mans.gcrmust sften accept the responsibility if proper

funds hnve not been set aside for adequate NDT,

if degigners did not properly

coordinate with production and NDT engineers to design a system that could be

efficiently inspected antibuilt, and if completed parts cannot be properly

inspected in the field.

Beceuse the nanacer plays such an important role,

special administrative directives have been published by”DoD. The guidelines

and principles given in DAP 11-25,

should receive seri.ms attention.

Mana


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(

Keeping communications active betweer, functional groups is important,

especially during the design phase.

Communication, which can be either formal

or informal,

often takes the form of written release statements required on

all design drawings by Quality Assurance (QA) and NDT engineers.

Since the

effectiveness”of communications dependa on the time, money snd personnel

available to

ake analyses, it is up to the manager tn determine the degree of

effort to devote to specific communications actions.

Communication during the production phase is especially required if there are

incomplete design decisions, since QA and NDT engineers cannot do their jobs

effectively until designers have established specific flaw limitation

requirements and allowable trade-offs.

Although it is true that msny testing

decisions cannot be made during the design phase, until the flaw limitations

are established,

the designer must remain on the project and in communicatnn

with QA personnel.

The manager must emplny sound management practices to encourage quality

resultg by fostering high morale and positive motivation among his

subordinates.

Most importantly he ust be provided with the means tn

establish accountability and given the”pnwer and the authority to take

definitive action when .necessary.

Table 1.4(2). Guidelines for administration of NDT (managers).

1.

Maintain integrity (clear separation of responsibilities)

between:

o Rate of production (Production Engineering).

o Quality of production (Inspection, QA, etc.).

2. Ensure adequate communications (before, during, and after) between:

o Designer.

o 9A.

.

0 Production Engineer.

o NDT Engineer.

o Materials Engineer.

“3.

Provide adequate personnel,

facilities and avenues for implementation.

4.

Employ sound management practices.

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1.4.3

PRINCIPLES AND CUIDELINSS FOR DESICNFH?S

To achieve a successful design, a designer has to deal with several

constraints, such as size, weight, weight distribution,

dimensional tolerances

and fits,

aterial computabilities, production capabilities, cost limitations,

strength, fatigue life, appearance, surface finish, etc.

Although e designer

should be careful about adopting unnecessary constraints, he should be aware

of the inspectability of his design and whether it will require NDT or whether

choices exist that could render NDT nonessential.

A designer who has a

background in NDT can ore readily reach this determination (taking into

account cost-effectiveness, safety, and legal obligations associated with

safety and reliability) and can ake decisions, when required, that favor a

successful NDT program.

One of the most important obligations of the designer, when NDT is determined

to be 3~C~S33Y;, :s to cotablish the

requirefients for

the inspection, with the

help of stress, material, and test engineers. If these limits are not

reasonable relative to the liDTmethods available, then trade-offs must be

considered.

One area that is seldom considered by desiGners is the use of internal

standards.

For exnmple, almost all ultrasonic inspections require a special

setup b’ithcomparisons to reference standards. Ideally, there must be a like

correspondence between significant factors within the comparison.

Reference

standards should perfectly match the test article in the type of material, the

hardness, the thickness, the surface finish, etc.

Test setups should produce

equal indications for equivalent flaws.

With very little extra cost,

cor,ysnefitacan be devel~psd thht hhvti Lideiruwn internal sianaartisdesigned

into them as an alternative.

When ar.andardsare designed into the component,

all the correlations required for surface finish, for type of material,

hflrdness,etc.,

are all automatically achieved and the inspection is greatly

improved in terms or time and reliability.

The arrangement of itaving the

designer create the NDT standard saves time and provides the desiRner with

important NDT knowledge.

Almoac all NDT testa, including radiof;raphic,eddj current, and ultrasonics,

can be improved by similar considerations.

Designers should exercise a direct

effort to improve the inspectability of the parts they design, not just in the

development and construction phase, but also in terms of inspection required

during the service and repair phases of the component’s life. Only a designer

can accomplish this desirable total life cYcle apprOach.

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Table 1.4(3).

Guidelines for designers.

1.

Determine if NDT is really required.

)

2.

Determine if the need for NDT can be rsmoved by:

Improving the design.

Using an over-design approach.

Usiug redundancy.

Using better materials.

Selecting better production methods.

Establishing better production controls.

.

Accepting more risks.

Substituting proof tests.

3.

If NDT requirements cannot be removed:’

Does the design allow NI)T?

(

Will trade-offs be necessary, or can trade-offs be found, to

make possible

Will internal

:IuTE: Sometimes NDT will

be done, use it to

be feasible, etc.

andior improve the NDT inspection?

standards be necessary and/or practical?

be.required by contract.

Therefore,

if NDT must

.vour advantflCe. The “se of cheaper material nay

1.4.4

PRINCIPLES AND CUIDEL1NE5 FOE PRODUCTION ENCINEERS

Production engineers alko work under constraints. Thej must produce

acceptable products within an assigned time schedule and fixed budget. Their

success depends upon the employment of both basic and technical knowledge, of

which optimal use of NDT is an important part.

Production engineers must constantly assess the smount of NDT required and

determine exactly where it is to be accomplished.

Forexanple; expensive

machine time cannot be spent cuttin& raw material into a finished product only

to find, at the-last cut,

an internal flaw that requires rejection of the

psrt.

Such flaws should be found before such operations are initiated.

/

1.4-7



20/46

Production engineers normally desire to perform NDT at the earliest possible

point in time, usually at receipt of raw stock.

The NDT engineers, however,

usually want to do NDT when the parts have the simplest shape with the most

uniformly prepared surfaceg.

Reliability engineers often want to do the ND?

after all uossible disturbing operations are completed. Usually, there is not

-.

sufficient time or money to do ell these inspections.

The final decisions

often rest with the project engineer who must meet overall budget and time

constraints.

Production engineers should also be aware that production methods and

controls,

aw times, establish the need for NDT.

Although selectinn of

production methods and controls that prevent flaws from occuring would, of

course, be ideal, trade-offs between the costs of using a more expensive but

less flaw-inducing method,

versug the cost of testing and possible rejection,

must be a consideration for every choice being umdk.

One of the most productive uses of NDT is the direct emplnpent of inspection

during the actual manufacturing prncegs.

For example, a ethod that

completely changes the approach to the

anufacturing process and weatly

increaseg

the reliability of the finished product is the use of ultrasonically

controlled cutting machines which determine material thickness as each cut is

made. Automatic tiDTcontrols such as these provide great opportunities for

increased productivity and reliability.

Table 1.4(4).

Principle and guidelines for production engineers,

1.

Determine the earliest point in time when NDT ig desired.

2. Ensure that the rate of inspection is adequate or initiated early

enough to maintain adequate stock levels.

3.

Know the &terial,

the reputation of the sources of the material, and

the characteristics of the production operations as affected by the

material.

4.

Select production operations and controls that minimize material

problems.

5.

Coordinate the NDT tasks with requirements from QA and Design.

6.

Use the science of NDT as a direct production control methnd where

developed and appropriate

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1.4.5

PRINCIPLES AND GUIDELINES FOR QUALITY ASSURANCE PERSONNEL

,

The information given herein should be taken only as

Quality Assurance (QA) personnel. Specific detailed

by each.of the separate branches of the DoD.

All QA

their respective manuals for specific instructions.

Eeneral guidelines for

instructions a“reprovided

personnel should refer to

Quality Assurance (9A) responsibilities extend over the full ND’Ispectrum.

The total magnitude of administrative and technical responsibilities depends

upon the size of the operation involved. However, whether only one individual

or many individuals are involved in the QA task, the following areas must be

considered as part of the QA responsibilities:

1.

2.

3.

4.

5.

b.

Train,

test, and classify inspection personnel and maintain their

records.

Know the availability, effectiveness,

and costs of NDT facilities and

operations.

Maintain teat records and reports.

Establish and maintain communications with design, production, and

program managers.

Maintain a’

“corrective action” system.

Maintain an advanced technolo~ical improvement program.

Administration of the QA task includes -control over personnel, NDT facilities

and data records. Personnel rosters, showing IJDT related education, traininc,

tests, test scores, qualifications, classifications, and appropriate medical

records should b maintained on all individuals responsible for NDT (including

those ostside of QA who are involved in NDT).

Comments on their abilities ani

limitations should also be included.

These records should be continually

checked and updated.

In addition, QA administration should,provide a formal

training, testing,

cor@g,

and classificati”on,program ”utilizing assigned

instructors and persomel to administer these areas.

Retesting and

reclassification of personnel should be done periodically on a continuous

basis with maximum time periods specified for retesting each time a

classification is assigned.

QA should maintain a current inventory of all ND1’equipment with ready

references to the “accuracy,resolution, reliability, maintenance schedule,

average downtime, and inspection rate of each item. In addition, racords

should be kept on all other factors that might impact on time, money, and

pereonnel.

Cost of labor, maintenance, electricity, and other power eources

must all ba monitored and kept current.

All of this information ia vital for

making the decisions that must be made by QA.

One of tbe msjor.hdm.iniatrative dutieg performed by 9A includes maintaining

inspection recordi and reports.

As a result, the following questions should

be considered by QA:

1.4-9



22/46

1.

‘m””n~Lecords arc to be

HIL-HI)E-’l28/1

kept’?

2.

I{OK10nG should they be kept?

3.

How shall they be maint~ined?

4.

How should they be purged or corrected?

5.

Who shall have access?

Many of these records must be maintained fo~ the life of the progran or the.

parts involved.

Communication is another large area of administration for QA.

Communication

with upper management, pro,iecten,.?neers, desicners, production and material

enCineers, facilities, and laboratory standards personnel should be

established findmaintained by OA.

In the technical area, QA ~hould proi.irleprcdesi~n support to help the

dcxiGners develop parts that are inspcctable to the degree necessary to assure

the,required reliability. QA sliould;IISO W able to check the completeness of

i.tw.esiCriers

‘ approach to lilT.

‘Qu.qli.y:ms”rance mu:;t support the :W:tP,

or initiation, of proriuction runs.

This support requires an understanding of exactly what is required, why it is

rvquired.

and all appropriate trade-offs thnt mW be Present.

Decisions on

exact methods to be used must be made. whether those methods are NDT or

others, and the standards or verifications

required must be established. It

Lhen becomes necessary for CIA to monitor the existing production runs to

,jll~urethat all ~riginal ~ssumptiarls are still valid, that all procedures are

being followed, and thnt proper records, reports, and interpretations are

boin~ developed.

t is essential that (3Am,ainLain o,.yscem~,

or detecting potential or actual

problems and expeditiously solvin~ those problems. These “corrective action””

s:;tems may consist of several items, includin~ formal report procedures,

review boards, and rejection tags for defective parts.

In addition, for any QA department to be successful over a’10ng periOd Of

time, it must recognize that changes must be made as technology is impmved.

QA should have a formal interest and obligation to stay up-to-date with the

state-of-the-art of NDT, thus allowing personnel to become knowledgeable and

experienced, so they can periodically improve NDT capabilities as new

developments occur.

Although funding for this area of effort is not always

available, it is essential to effective preplanning activities that personnel

have access to current technology.

It does not hsve to be assumed that QA accomplishes all the details of everY

assigned task in all these areas, either adminiatratively or technically. But

it is QA’s responsibility to see that, oversll, these details are accounted

for or that reports to the contrary are made. Much of QA”s success will

depend upon the quality of com..unications established with all the involved

areas and the formulation of decisions based upon their cOmbined .inPu=.

1.4-10



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(

MIL-HDBK-728/1

Table 1.4(5). Guidelines for oualitv assurance

personnel.

A. Administrative Areas:

1.

Administer Personnel Training and Classification (including resters,

NDT education, training, tests, test scores, qualification. ratings,

work classifications, medical historieg, NDT work experiences, ‘and

evaluations by supervisors).

2.

Maintain Current Inventories of NDT Facilities to include specified

accuracy, resolution, reliability, maintenance schedule, average down-

times, inspection rates, availability of operators, operator costs,

depreciation rates, maintenance costs, availability of power,

operating costs, etcl

3.

Maintain Inspection Data’Records - What records, hnw maint~ined, h>w

long, how purged and/or corrected, who has accesa.

4.

Establish Communication (Policies, Planning, Scheduling,

Coordination, Proposals, etc. ) with and between administrators,

p:ojact engineers, designers, production, material, and facilities.

B.

Technical h~eno

1.

Support Design Drawing Reviews - Assist in checking and approving

completeness of designers approach, ‘“tradeoffs, and decisions.

2.

SUFpOr[ t l=?rOgrSn -

lctc=inc exactly vh,: is required, why it is

required, and what methods are to be used.

Establish procedures for

chosen method,

standards, reports, and data controls.

3.

IJetectand Solve Problems (Corrective Action) - Establish corrective

action review boards, and rejection

tags.

4.

EncourxKe Hesearcb aptiIkvclo?nent

(R & D) - Sca.vingup with the

state-Of-the-.arL.

1.4.6

PRINCIPLES AND CUII)ELINES’FOR NDT ENGINEERS

Some ND? engineers nay be directly involved with receiving and inspection,

quality assurance, or production activities, while other NDT en&ineers are

ase.ociaLea with research and development efforts.

Different qualifications

are often required in each of these areas.

Basically, however, it is the NDT

engineer who must understand the principles of each type of nondestructive

test and the specific limitations of those tests.

He must be able to recognize

which inspection procedures are proper or adequate for the desired results and

he must understand the results and their interpretation.

/

(

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MIL-HDBX-728/l

ln order for the NM’ engineer to perform his duties to the fullest, he must

have certain specific information.

He must know the materials involved and

how the part was fabricated.

He

ust know what defects

and/or

properties are

to be detected andlor measured.

He must be able to identify the kinds of

false indicating that may be encountered so that they may”be properly

considered.

It is the NDT engineer who must often communicate and explain the

differences and difficulties when what is requested differs from what can

actually be obtained.

Because the NEW engineer knows the equipment and personnel available, he can

provide a significant amount of data necessary for scheduling nondestructive

tests.

Sometimes an NDT engineer receives complete instructions from QA where

test plans, procedures, and standards have all been ptiedetexmined.

It is a

requirement thet the NDT engineer double check these procedures and standards,

and essentially,

reverify their effectiveness.

The NDT engineer will normally have NDT technicians under his direction, and

the treining and instruction of these technicians will be one of his prima~

concerns. He must understand each technician’s ability to handle complicated

tasks and the limits or the “’confusion” level with which an individual

technician can

adequately

cope.

These factors will greatly influence the

assignment of tasks and the degree of independence that can be given to each

technician.

All of the preceding factors will affect the type Of inspection rOutine that

an NDT engineer will institute.

The NLYTengineer should also be cognizant of

the sorting routines and scanning methods that have proven to be the most

reiia”Diefor his personnel to roiiuu it,any particular sit.u~tior,.

k%ea a

vsriety of flaws are to be detected, the approach, sorting routines, order of

the search, number of repeats in the search operation, direction of scanning,

scanning rate,

and type of data comparisons (digital or analog) that must be

observed will affect the reliability of the results.

Often, a search for one

kind of flsw at a time, on one type of part, will serve to remove some of the

complexities which exist for multiple parts and fIaws, as Well as to establish

rsliabillty.

One parameter beyond the control of the NDT engineer is the rate at which the

presence of flaws is indicated.

When parts are relatively “clean” and free of

indications, or alternately, when there are a great many indications, the

percentage of flaw indications missed usually increases,for ost inspectors.

NDT engineers should be aware of tha frequency of occurence of the flaws to be

detected and adjust the inspection routine as necessary to maintain the

required reliability.

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Table 1.d(6). Guidelines for l:DTengineers.

1.

““

2.

3.

4.

5.

6.

7.

8.

KflOU

Know

Know

Know

exactly what is wanted and why.

the part and/or material to be inspected.

the defect and/or property to be detected andfor measured.

limitations of equipment and pergonnel.

Establish time requirements and schedule.

Double check exact procedures and standards raquired.

Provide the technician with adequate material, facilities, and

working conditions.

Ensure that an honest and complete report is made (that both

assumptions and lirnitationa are known to those.receiving the

l-sport).

Provide information and training to technicians, and

guidance and suggestions to QA, designers, and msnagers.

This is

done both formally and informally. These lines of communications

should be established and well used.

Information that should be provided to the NDT engineer by QA or

( “*

project engineer.

1..4.7

PRINCIPLES AND’CUIDELII:ES FOR NDT TEcHNICIANS

Technicians are the final key r,IJuccessful (DT. The personal efforts of

knowledgeable and experienced technicians can often save a pro&ram ntherwise

doomed to failure.

Likewise, a seemingly successful program CRO fail if

proper rssponies to indications a“renot maintained by the technicians.

Even though a technician’s task -- to note all exceptions tO that which is

nnrm.al-- app6ars fairly simple, it “can often become complicated.

In fiDT,

meaningful observations may consist of only slight changes or fleeting signals

that can easily go undetected -- particularly if they randomly occur between

extensive amounts of unimportant data.

Sometimes, the.problem can develop

frotntoo much information. If a technician is being presented with a

multitude of nonrelevant or false indications that must be continuously

rejected, valid indications can sometimes be automatically rejected as well,

through force of habit.

A good technician will be aware of these problems and

their impact on NDT and will consciously guard against them.

The danger of fatigue and hypnotic effects on the technician must also be

consciously fought sgainst,

~d the technician should not hesitate to ask for

a break or change in routine that might prevent these kinds of difficulties

from developing.

Present efforts to automate all inspections exist msiply

because of these hiunsnweaknesses.

However, since automatic inspection systems are incapable of noticing all the

various types of exceptions that a technician can, technicians will still be

needed snd valued for their technical knowledge and attentiveness to detail.

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MIL-HDBK-728/l

Ceneral guides for technicians include: 1) Not hesitating to ask questions or

double-checki~ procedures releting to”

the

“NDT work: 2) Recording all NDT

tasks and results; 3) Always checking all dial settings each time an

instrument is used for a new setup; 4) Knowing the capabilities and

limitations of the equipment is essential.

Table 1.4(7).

Guidelines for NDT technicians.

1. Be aware of the dangers of fatigue and hypnotic effects (Know how to

fight these effects.

Do not hesitate to ask for a break when any

sign of these effects are present).

2. Always note all exceptions to that which is normal - they may be

important.

3.

If you are not sure if you should ask

should.

4.

Always record everything done in NUT.

about something, YOU probabls

5.

Always check all dial settings each time an instrument is used for a

new setup.

6. Know your equipment and your own limitations.

/

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1.5 CHOOSING TEST METHODS

Choosing a proper NDT method requires a knowledge of the types of flaws that

must be found,

their maximum acceptable limits in size and distribution, and

their possible locations and orientations.

Also the presence of all other

possible variables that may affect the inspection must be

known.

This might

include the orientation and accessibility of the part, the part’geometry and

size, internal variables in densities, ‘etc.

‘l’his

knowledge

must then be

coupled with knowledge of the basic principles and limitations of all NDT

ethods, their availability, and costs.

One must also be fsmiliar with the

requirements and availability of atandarda to employ thase nethoda and the

typs of records required. (See Table 1. 5[1 at end of this section. )

The appropriate method may conaiat of iaveral separate inspections. One

inspection by itself may indicate the presence of a possible flaw and other

inspections may be required to confirm or verify the original indication.

When the choosing of NDT methods is done routinely, then it is important that

a list of average basic costs of each available

ethod is formulated. An

example would be as follows:

LIST OF

PRELIMINARY SET UP

ACTUAL TEST COSTS

AVAILABLE

REQUIREMENTS

LABOR ADDITIONAL

KETHODS

LABOR STANDARDS

NH/Part

COSTS

AVAILABILITY

. ,,

Liquid

Penetrant Minor Minor 0.8 Minor

Good

Rag ?articie Minor

i.iino i.i Iiinor

in heavy

use

Eddy Current

Possibly

Ye9 -

...-.

“-~.2 ““ “-None

Good -

extensive

Ultrasonic

Possibly

Nollrlally 2.0

Paper

Not working

(C-scan)

exten3ive extensive

until next

month

X rays Minor Routine

2.0

Film”“and

Good

development

With such a chart,

one can start with the cheapest method available and then

progress through tha list to the first available method that will meet

acceptable detaction limits.

Thase lists must be individualized for each

oparation, taking into consideration how modern the available equipnent and

facilities are and the level of personnel staffing. Although these lists can

provide some broad guidance, they should not be used as a definitive

standard. Costs for each tast vary and the ma.xim~ or minirn~.of.On? test

mathod may, in some cases, overlap the costs for another test method.

Tha choice of a proper NDT nethod requires an understanding of the bssic

principles, and advantages and disadvantage of all available NDT test

methods. Detailed knowledge of their comparative effectiveneag, availability,

and costs are all critical in

aking the corract decisions.

Tables 1.5(2)

through 1.5(6) (it the end of this section) list some of the general

advantages and disadvantages of a number of general NDT methods. All NDT

users should maintain similar lists, basad upon axperiance with their

particular equipment.

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There are times when the choice of

ethods is very clear.

When small

delaruinations between layers deep within a flat composite panel must be

detected, an ultrasonic test of some type will almost

always

be chosen. If

surface cracks on an iron part were to be detected,

liquid penetrant, magnetic

particle, ultrasonic, eddy current and X-my tests could all be individually

considered. If porosity were to be found,

a quick ultrasonic C-scan might be

used to locate potential areas, followed by X rays concentrated in those areas

identified by the C-scan, to confirm if porosity is really involved and, if

so, to what extent.

Since the difference between success or failure depends on knowing the details

of the

specimen

and/or

material

being inspected, many NM’ coumes properly

begin with a study of raw material manufacturing processes to indicate the

orijzinand causes of flaws in castings, ingots, and forgings.

The reshaping

and redistribution of the flaws in subsequent manufacturing processe3 must be

understood.

Although a study of these flaws and processes will nat be given in this

handbook, the importance of this area should not be minimized. All NDT

personnel should be familiar with: porosity, nonmetallic inclusions. pipe.

macrosegregation, cold shots, cold shuts,

hot tears,

shrinkage cracks,

blowholes, migruns. forging laps, stress cracks, grinding cracks, fatigue

cracks, galling, and gcale.

They should know whera they occur or can be

expected to exist,

and what i,mpactthey may have in each of the test methods.

The comprehension that flaws are to be expected does not always exist with

those who are inexperienced .

Yet it is the first step in chooging a proper

NDT method.

Knowing what the fiaws might be and where to look for them is the

next step. Therefore, a study of materials, as well as the relevant produc-

tion and manufacturing processes, is vital to the choice and administration of

an NDT program.

Lastly, the most critical (and of ten the most unavailable) dats for determin-

ing an appropriate method involves what the acceptable limits on the size of

the defect are.

Those limits determine whether the method would he feasible

and how expensive an effort would be required.

Figure 1.5(1) expresses the

importance of this size tolerance.

References to sections 1.4.3 (Designers),

1.4.’4(QA) and 1.4.1 (General Principles) all discuss the importance of

defining this limit.

1.5-2



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1

(

Table 1.5(1). Choosing proper NDT ethods.

1.

Determine the material to be inspected and the type of flaws or

difficulties common to that material.

2.

Detemine the material manufacturing processes and the type of flaws

or inconsistencies associated with those processes.

3.

Know the part to be inspected and determine “itsdesign requirements

ao that critical flaw limits can be established.

4.

Know the baaic principles and limitations of all NDT methods.

5.

Know costs and availability of NOT personnel and facilities.

6.

Determine what starldards are required and their availability.

7.

Determine what records and controls are rsquired.

Table 1.5(2).

Advantages and disadvantages of liquid

penetrant.

Advantages:

1. Usually very cheap (often is the cheapeat methOd).

2.

ija~aily quick, even for iarge pnrt.s.

3.

Can be portable

4.

Reasonably easy

Disadvantages:

1. Can only detect

2.

No automatic or

(taken

to

test site).

to interpret.

defec~s opened to the surface.

permanent records.

3.

Often requires a pre-cleaning step.

4.

Use of fluorescence required for maximum sensitivity.

5.

Not good for rough or porous surfacea.

(

6. Penetrants chemically attack some rubbers and plaatics, and

should have a low’sulfur and/or chlorine content when used with

certain

stainlesa steel, nickel, or titanium materiala.

/

1.5-3



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MIL-HDBK-728/l

able 1.5(3).

Advantages and disadvantages of magnetic particle.

Advantages:

1. Surface or near surface flaws can be detected.

2. Reasonably cheap and quick.

Disadvantages:

1.

Magnetic type materials only.

2. No permanent records.

3.

Uust often demagnetize parts following test.

4.

Surfaces can be marred vhere contact probes are used.

Table 1.5(4).

Advantages and disadvantages of eddy current.

Advantages:

1. Surface or near surface flaw can be detected.

2. Very sensitive to any variables such as :

geometry (thickness, stand-off).

surface roughness.

frequency.

electrical conductivity.

magnetic properties.

cracks.

3.

Direct 60/no-go type answers can be obtained quickly.

4. Portable.

5.

No

physical contact required (can be accomplished in a vacuum) .

6. Not too expensive.

7.

Easily adaptable to production line situations (electrical

signals for electrical controls) .

Disadvantages:

1. Must involve one or more layers and/or surfaces that are

electrically conductive or agnetic in nature.

2.. Requires skill when many variables are involved.

3.

Adequate reparation of variables cannot always be Achieved,

/

1.5-4



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MIL-HDBK-726/l

(“

Table 1.5(5).

Advantages and disadvantages of ultrasonics.

Advantages:

1. Internal inspection method (the deepest penetrating method).

2. Can be adapted for thick or thin panels.

3.

Extremely sensitive to many speciinanvariables:

porosity.

delamination.

micro cracks.

geome try

density changes.

4.

Many

grain or fiber size.

orientations.

test control variables:

transducer frequency.

transducer size.

transducer t,ype.

transducer focal lcn~th.

type of test (immersed, contact, or jet).

llisadvantaCes:

1.

Non-linear responses (variable relationship between flaw size

and indication size).

2.

Sometimes too sensi tive (impossible CO separate out desired

parameter).

3.

Often limited by geometry and surface roughness.

4.

Often must have special standards (especially when details are

as small or smaller than the width of the inspection beam) .

/

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MIL-HDBK-728/l

Table 1.5(6).

Advantages and disadvantages of X-rays (radiography).

Advantages:

1.

Good internal inspection ethod.

2.

Excellent geometric representations.

3.

Good sensitivity, .2%is reasonable.

4.

SmaIl detsils are visible (the limit is often the size of the

grains on the film being used).

Disadvantages :

1.

The image is a shadow only (The shadow varies only as the amount

or density of the material varies.

Therefore, it can “see”

missiag material, but if a delamination exists perpendicular to

the X-ray beam with aterial pulled apart but not issing, an X

ray will not detect it).

2.

Sometimes expensive in time, lflbor,and facilities.

3.

Personnel safety requirements.

4.

Sensitive to orientation of cracks.

/

cOST CURVE VARIESWITH

EACH METHOD ANO EACH

MATERIAL AND PART

OESIGN,ETC

I

1, IMPOSSIBLE

—----

.—

I

t-l----sO’s’BLE

I

I

1

I

b

0

+1/4IN.

? 1/2IN.

SIZETOLERANCE

/

Figure 1.5(1). Cost curve.

1.5-6



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1.6

GLOSSARY

Classifications (for NDT persomel) .

Personnel classifications can be

ade by

nondestructive test methods, by specific equipment, or by specific product

lines in which qualifications have been obtained,

Corrective Action.

Action taken ‘(or plans for actions to be taken) for

solving problems that occur during production.

Correlation.

Establishing relationships between facts or events.

Critical” Flaw Size.

The minimum extent of a flaw (e.g.. miiim~. depth.

length, etc.)

that prevents achievement of the designed goala for a particular

part.

Defect.

Any condition of a part that prevents achievement of a designed goal

is a defect. A flaw that is of critical size or larger is a defect.

Delamination. A delamination is a partial or complets separation between two

layers of a material which should be bonded together.

Discipline.

A specialty of professinn or training.

Documentation. Writteri or recorded proof, usually includes a ‘picture” or

(

other data recording msde in a controlled test.

Documentation should include

names, date, equipment, and all other vital information necessa~ to confirm

LIW stcitusof & part .crthe results of a teat.

Fatigue Life.

The expected number of load cycles that a part can withstand

and still perfoxm adequately.

Flaw.

Any imperfection in a part can be considered to be a flaw.

By this

~nition, all parts have flaws.

Many flaws are too small to be of concern.

Some flaws may be large enough to cause a part to fail. When flaws are large

enough to cauae failure, they can be called “deects.”

Flaw Size Limitation (eee critical flaw size).

Indications. Any signal or markings obtained in a test is an indication.

Indications mu-st be interpreted.

There can be falae indications (not due to

the material variable of concern) and valid indications.. There can be

acceptable indications and rejectable indications.

Integritv. Integrity ia a meaaure of the completeness of a part, or the

property of being solid or continuous, with no break in tha uniformity of the

part.

Life-Cycle.

The complete history or activi ties associated with a part, from

its manufacturi~, to ita ultimate utility as a waste product.

(“

Nondestructive Evaluation.

(See Section 1.3).

..’

1.6-1



34/46

MIL-H:)li[-7?F/’:

CLOSSAftY (COI TINUED)

ilondestructive.Insuection. (See Section 1.3).

Nondestructive Testing.

(See Section 1.3).

Permanent Record. Any automatically produced “’picture”’r recording of data

(e.g., X-ray negatives, C-Scans) abtained from a test which i.spermanent and

can be used at any time to confimn the results of a test. It forms part of

the Documentation that might be specified for particular inspections.

Qualifications (for N T personnel).

The minimum education, knowledge and

experience required of an individual to use a particular NDT method. ASNT

qualifications include three levels: I, II and III.

All inspection super-

VIS.:TSshould be lCVC1 11 or higher.

Cluality Assurance (QA).

Qualit.v Assurance can be the organization, the con-

trol, or the actions taken to ensure th~t parts will meet all design goals.

particular group 1s often ~ssigned responsibility to ensure that Parts are

(

A

c~rrcctlx built, inspected and tested to confirm their quality and reliability.

llel]:ib]l]Ly. Confidence in the achievement of speciflc coals, often expressed

in statistical terms.

Reference Standards. Any part or image that is used to judge the status or

acceptability of another part or image can be called a reference standard.

Standards. The bsse upon which or by whirh other variables are judged or

measured.

Tailorinc. The act af changinc someth]nc from one state

or

condit>on to

another state or condition to better fit or apply to particular circumstances.

Trade-off.

Mutually exclusive events or condi tion% often require a choice

between them.

A trade-off is exchanging one state or condition for another,

with subsequent Rains rindlosses.

1.6-2



35/46

MIL-HDBK-72B/l

The following

1.7 BIBLIOGRAPHY

ists of Specif cations, Standards, Handbooks and other

dditional sources of information to aid in an.vpublications are provided as

particular NDT problems that may arise.

1.7.1

GOVERNMENT DOCUMENTS

TECHNICAL ORDERS

Air Force TO 00-25-224

Air F“rce

TO

3311- 1-1

Navy NAVAIR 01-lA-16

A 1711y

TM 43-0103

Welding High Pressure & Cryogenic Systems

(Section 4

- Nondestructive Inspection by

Ultrasonic and Eddy Current Methods)

Hondestructi.x. Testir& lethods

(Chapter 1 - General, Chapter 2 - Magnetic

Partical Method, Chapter 3 - Eddy Current

Method , Chapter 4, Ultrasonic Inspection

Method, Chapter 5, Radiographic Inspection

t4ethod, Chapter 6, Floureacent and Dye

Penetrant Method).

KILITARY STANIJARDS AND SPECIFICATIONS

MIL-STD-?71

MIL-STIJ-79EI

}11L-I-6870

MIL-STD-41O

MIL-STfI-721

Nondestructive Testing Requirements for Metals (Radiography,

Magnetic Forticie, Liquid ?enetrant, Leak Testing. Ultrasonics) .

Nondestructive Testing, Welding Quality Control, Material

Control & Identification & Hi-Shock Test Requirements for PipinC

System Components for Naval Shipboard Use (Radiography, Magnetic

Particle, Penetrant) .

Inspection Requiremen~s, Nondestructive for Aircraft Materials &

Parts (Magnetic Particle, Penetrant, Radiographic, Ultrasonic,

Eddy Current).

Qualification of Personnel.

Definition of Terms for Reliability, Maintainability, Human

Factors,

and Safety .

1.7-1



36/46

MIL-HDBK-728/l

MILITARY QUALITY ASSURANCE PAMPHLETS

Af’lCP702-3

Reliability Handbook (Army Material Command)

DAP 11-25 Life Cycle Management Model for Anuy Systems (Department of the

Army)

NASA PUBLICATIONS

NASA SP-3079, Nondestructive Evaluation Technique Guide, A. Vary (U. S.

Covernmant Printing Office, Washington, DC) 1973

NASA 5P-5113, Nondestructive Testing - A survey, (U. S. Government Printing

Office, Washington, DC) 1973

NBS-PUBLICATIONS

NBS

Nandbook 14, General safety standard

far installations usinc non-material

x-ray and sealed gamma ray sources, enereiez up to 10 Me V (U. S. Government.

PrintinflOffice, Washington, D.C.)

NE SHandhoo ?50, X-ra:;protection de~ifln(Ij.

3. Government Prlntlng Office,

Washington, D.C.)

NBS

Handbook 57, Photographic dosimetry of X and


37/46

5.

6.

7.

6.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

23.

21.

}lIL-t{DBii-728/l

Annual Book of ASTfiStandards, Part 03.03, “Metallography; Nondestructive

Testing”’ (American Society for Testing and Materials, Philadelphia) 19@0.

Classroom Training Handbook, CT-6-5. ‘“Nondestructive.Testin&. Eddv

Current, ” Generai

Dynamics”Convairl

San Disgo) 1979 (Secon~’Edition) .

ClassrOOm Training Handbook, CT-6-2,

“’Nondestructive Testing, Liquid

Penetrant, “ (General Dynamics Convair, San Diego) 1979 (Fourth Edition).

Classroom Training Handbook, CT-6-3, “Nondestmctive Testing, Magnetic

Particle,” (General Dynamics Convair, San Diego) 1977 (Second Edition).

Classroom Training Handbook, CT-6-6, “Nondestmctive Testing,

Radiographic,” (General Dypamicg Copvair, San D>ego) 1967.

Class&mn Training Hand”book, CT-6-4,

“Nondestructive Testing, Ultrasonic,”’

(General Dynamics Convair, San Diego) 1981 (Second Edition) .

Classroom Training Handbook, CT-6-6, “Nondestructive Testing,

Radiographic ,“

(General Dynamics Convair, San Diego) 1967.

Nondestructive Testing ‘Handbook, t?.C. 14cMaster, Ed., (Ronald Press, N.Y.)

1959.

Nondestructive Testin&, Warren J. lcGonnsgle, (McCraw-Hill, N.Y.) 1961.

Metals Handbook, Vol 11, (American Society for Metals, Metsls Park, OH. )

lY’(6(8th Edition).

Suggested “Course Outline for Training NDT Personnel, V. L. Stokes (ASNT,

Columbus. ) 1976.

NTIAC Handbook, R.E.Engelhardt, Ed., (Southwest Research Institute, San

Antonio.) 1979.

Ultrasonic Testing, J. Szilard, Ed. , (John Wiley & Sons, N-Y.) 1982.

Radiation Detection and Measurement, G. F. Knoll, (John Wiley & Sons,

N.Y.) 1979.

Ultrasonic Testing of Materials, J.

and H. Krautkramer, (Springer-Verlag,

Berlin) 1977.

Advanced Ultrasonic Testing Systems, H.

S. Silvus Jr., (Southwest Research

Institute, San Antonio) 1976.

Basic Physics in Diagnostic U1 trasound, J. L. Rose and B. B. Goldberg,

(John Wi eya Sons, N.y.) 1979.

Principles of,Magnetic Particle

Chicago.) 1967.

Introduction of Electromagnetic

(Krieger, N.Y.) 1979.

Tegting, C. E. Betz, (Magnaflux Corp. ,

Nondestructive Test Methods, H. L. Libby,

1.7-3



38/46

~~ .

23.

2A.

25.

26.

27.

.?6.

29.

30.

31.

32.

:3.

’34.

1.7.

N L-lll)RK-”1’2&’I

Principles of Penetra”ts, C. E. Bet: (MaKn~flux Corp. ,

hcaustic Emiss] or

Techn>qaez and A?Dlicatians, J. C. Spa””er, (lntex

Corp. , IL.) 1974

Introduction ta Nondestructive Testl”g, G. P. Hayward, (America” Society

for Quality Control, WI. )

Techniques of Nondestructive Testinc, C. A. Hogarth and J. Betz,

(Butterworths, London) 1960.

Quality

Control Handbook, J. M. Juran, Ed., (McCraw-Hill, N.Y.) 1962,

Ultrasonic Technology, E. Goldman (Reinhold, N.Y.) 1962.

ultrasonics, B. Carlln, \}lcCraw-Hill, N.Y.), 1960.

STP 624, Nondestructive TestinC Standards - A Review, H. lkrger, Ed.,

(ASTM, Philadelphia) 1977.

Radlograph,v

in Nodern Industry, (F;astmanKodak, Co., Rochester) 1980

(Fourth Edition).

Practical Appll rations of Neutron F:atiloflraphy

and GagL~, H. Berger, Ed.

(ASTM, Philadelphia) 1976.

Physical Ultrasonic, R. T. Beyer and S. V. Letcher, (Academic Press, 11..)

1969.

Research Technlaues in Nonaestmctlve Te~ting, R. S. :har~e, Eli.. 4

Volumes (Academic Press, N.Y.) 1989.

NASA SF-5113, Nondestructive Test]nc - A Survey, (U.S. CctvernmentPrint~n,y

Office, Washin~ton D.C.) 1973.

2

h’HER5TO OBTAIN SPECIFICATI(Jr :;

ND STANDARDS

All

U. S.

Department of Commerce, National Bureau of Standards Handbeaks are

available from the Superintendent of Doc”me”ts,

Government Printing Office,

Washington, D.C.

20402.

All other government. agency spec]f]catl~ns or standards are under the central

of the Department of Defense.

A1l requests for copies af specifications, standards, and qualified products

lists should state the title a“d identifying “~ber e“d should be ~“bnitted to

Commanding Officer, Naval Supply Depot, 5801 Tabor Ave., Philadelphia, PA

19120, Attn.

- Code CDS, except:

1.7-4



39/46

MIL-}{BK-728/l

a. Copies of specifications, standards and qualified products lists raquired

by contrac Cors in connection ith specific procurement functions should be

obtained from the procuring agency awardin~ the contract or as directed by

the contracting officer.

b. Federal Specifications and Standards and Military Book Form Standards ‘will

not generally be furnished by the Naval Supply Depot to commercial

concerns unless required in conjunction iith a bid or contract, or for

sufficient other justification. Copies of federal documents may be

purchased from the Business Service Center, General Service

Administration, Washington, D.C. 20405.

Most book-form Military

Standards may be purchased from the Superintendent of Documents, U.S.

Government Printing Office, Washington, D.C. 20402.

c. Only current, “in effect”

issues of standatiization documents will be

available from tk,eNaval Supply cpot. Copies of canceled or superseded

documents required for contractual purposes will have to be obtained from

the contracting office of the concerned service.

a.

Information regarding obtaining DoE “standards relative to the Division of

Reactor Development and Technology may be obtained from Oak Ridge National

Laboratory, P.O. Box X, Oak Ridge, TN 37830.

All specifications or standards as issued by the organization.? listed below

(“

are available di rectl.yfrom the organization at the address given.

.AE S

AIA

AIS1

Al. AsSOC.

ANS

ANSI

American Bureau or Siiippillg

45 Broad Street .

New,York, NY 10004

Aerospace Industries Association of America

1725 De Sales’ St. , NW

Washington, DC 20036

American Iron,and Steel Institute

1000 16th St.,,NW

Washington, D.C.

20036

The Aluminum Association

420 Lexington Avenue

New York, NY 10017

American Nuclear Society

555 N. Kensin@on Avenue

La Gra~e Park, IL 60525

American National Standards Institute, Inc.

1430 Broadway

, New York, NY 10018

1.7-5



40/46

MIL-HDBK-728/l

AH

ASME

ASNT

ASTM

AVS

AWS

ICRU

MSFC

NCRP

SAE

American Petroleum

l rwti tute

50 iiest 50th Street

New Iork, NY

10019

American Society of Mechanical Engineers

345 East 47th Street

Ueu York, NY

10017

American Society for Nondestructive Testing, Inc.

4153 Arlingate Plaza

Caller 28518

Columbus, OH 43228

American Society for Testing and Materials

1916 Race Street

Philadelphia, PA

19103

American Vacuum Society

335 East 45th Street

New York, NY 10017

American Welding Society

2501 N.W. 7th Street

Miami, FL 33125

International Commission on Radiation Units

7910 Woodmont Avenue, Suite 1016

Washing coft,1)..

2COL4

National Aeronautics and Space Administration

George C.

Flarsh811

Space Flight Center

Huntsville; AL

35812

National Commission on Radiation Protection

NCRP Publications

P.O. BOX 4867

Washington, D.C.

20008

Society of Automotive Engineers, Inc.

400 Commonwealth Drive

Warrendale, PA

15096

1.7-6



41/46

(

MIL-HDBK-72f3/l

1.8 I iDEX

Administrators

Definitions

(Format for handbook)

(NDT, NDI a,ndNDE)

(Glossary].

Designers

Liquid Penetrants, NDT Method

Sddy Current, NDT Method

“E~-in+6rs

Clossaxy

Guidelines

Index Guide

MagnetlC Particle, NDT Method

Military Handbooks

Organization (of Handbook)

Organizations (Addresses)

Principles

Production Engineers

Publications (Commercial)

Quality Assurance

References

(User’s Guide)

(Bibliography)

Revisions

(Guides)

(Procedures to Recommend Changes)

Scope (of Handbook)

Technicians

Ultrasonic, NDT Method

X-Rays, NDT Method

Section

1.4.2

1.2.4

1. 3

1.6

1.4.3

1.5

1.5

1.4

1.6

1.4

1.2.3

1.5

1.7.3

1.2

1.7

1.4

1.4.4

1.7.6

1.4.5

1.2.2

1.7

1. 2. 5

1. 0

1.1

1.4.7

1.5

1.5

1.8-1



42/46

1.s-2



43/46

1.9 NOTES

... . .

1.9.1 KIL-HDBK-72811, 12, 13, /4. 15 and /6 supersede the f0110win8

documents:

MIL-HDBK-54

15 October 1965

MIL-HDBK-55

1 April 1966

ML-HDBK- 726

10

June 1974

M L-HDBK- 333

10

April 1975

APICP702-10

Apri 1 1970

I

Custodians:

Army -- MR

Navy -- AS

Air Force -- ?0

Review activities:

Preparing activity:

Army --

MR

Project No. NI)TI-0047

Army -- AR

Navy -- OS

WP ID-1336P/Dl~C OO1OV.

POR AKMRC USE ONLY.

1.9-1



44/46

FllL-1{DNK-72Ei/1

THIS PAGE INTENTIONALLY LE?T BLANK

1. 9- 2



45/46

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O+V+OW. 7%b 1-M -Y ~ d=@b-t. fo* dOrU h km tndhtod, taped OIMI h h + (DO NOT STML&, , -d

tikd. In bhrk 6, & M WC@ - tibh IbOUl @CUIU pnbkm ~ rudt w - wb,M rgquind hterpmwtio”. .M

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candde-d.

NOTE: ‘I%u (OMI IMY DOt be ~ to nquwl cmpiei of documeau, mar w uquat aim dtitiocu, or .Iuificntkm d

cxlflcstlom requirwnenu on current rmtmcti. Gmmenu submltled on lbh kwrn do nol corufltute or imply tulhorimtian

LO -iw my parlim of tbe mfemwed document( ) or to

mend rontrsctud requkiemeow

Fold

d.”

,JdI I .u,

oEP4nTMENTor THE&RMv

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NEcEs5aFl

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UN’4TC0 s7A7E

BUSINESS REPLY MAIL

F,I+S7l-ass

ERMIT

o. ,2052

WAS” ONG,OI’4o c

POSTAGE WILL EE PAID BY THE DEPAI?TMENT OF THE ARMY

Director

U.S. Army Materials Technology Laboratory

ATTN:’ SLCHT-FYSR-ES

Watertown, HA 02172-0001



46/46

STANDARDIZATION ODCXMENT IWROVEMENT PRofosAL

h htnulbu -

RpuT ~)

00 CUUt NT UUUm m

2. WCUWWT Till.,

MI L-1llJHK-7?8/1

NONDESTRUCTIVE TESTING

m

WAUE 0S 9U8Mtl_ll N0 OMOANl?.AT1m

4. TVM OP OmOANIZATlON Ma -,

/


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